Slip resistant mat and method and system for making same

ABSTRACT

A system and method for making a slip resistant mat can include assembling parts with predetermined geometries to form a mold that can be used for making slip resistant mats that have channels to account for moisture between the mat and the floor. The unique geometries of the parts which form the mold can be manufactured efficiently and with reduced costs. The mold of this invention can be used to make slip resistant mats with channels that can both dissipate water and offer a high degree of mat to floor surface contact.

This claims priority to U.S. Provisional Patent Application Ser. No.61/781,148, filed Mar. 14, 2013 and is a continuation of PCT ApplicationSerial No. PCT/US13/54488, filed Aug. 12, 2013, each of which is herebyincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to slip resistant, anti-skid oranti-creep mats. Specifically, this invention relates to such mats and amethod and system for making slip resistant mats.

In the past, floor mats, consisting of rubber backed carpet tuft, weremade with either a smooth back, primarily for solid or non carpetedfloors, or with a variety of “grippers” or “cleats” arranged to reducethe movement of the mat on carpeted floors. However, both of theseapproaches resulted in floor mats that were not skid resistant on smoothfloors, especially those floors with residual moisture under the mat,perhaps from the moping of the floor and then the mat being replaced, orthe mat being slightly damp when delivered and rolled out. In suchcases, the water on the back of the mat becomes a slip hazard. Themovement of the mat in the gripper/cleat mat design results from theforce of foot and vehicle traffic on the mat which causes a deformationaround the compressed area and then upon removal of such force the matreturns to a different position. For the smooth back mats, movement ofthe mat results from similar forces and the lack of any device orfeature intended to secure the mat in place.

A number of approaches have been taken to attempt to reduce the movementof mats. One known approach to the problem is to fasten the mat to theintended surface by various devices, such as that suggested by Kesslerin U.S. Pat. No. 6,068,908 which utilizes a system by which a mat isfastened to the surface using a clip system. While this approach iswell-developed, it results in floor mats that are difficult orimpossible to move from place to place and the structures required toattach the mat add cost to the mat and difficulty to the installation.Also, attached mats are more rigid.

Another approach involves the use of a frame into which the mat isplaced, such as the frames used by Moffitt, Jr. in U.S. Pat. No.4,361,614 and Kessler in U.S. Pat. No. 6,042,915. The frame can belocated upon the flooring surface or inlaid to be flush with theflooring surface. In either circumstance, unless the frame is fastenedas mentioned above or embedded in the surface, the frame still has atendency to shift on the surface. If the frame is fastened or embedded,the other problems mentioned above still remain.

Another approach involves the use of suction cups, such as thosecommonly found on shower and bath mats, examples of which can be foundby Lindholm in U.S. Pat. No. 6,014,779 in which the corners of arectangular mat are held by four suction cups and by Gavlak in U.S. Pat.No. 2,081,992 in which a plurality of suctions cups holds the bathtubmat to the surface. While this approach provides acceptableslip-resistance for light shower and bath mat applications, traditionalsuctions cups are not sufficient to provide sufficient anti-skiddingforces to prevent slipping and movement in high traffic and high loadareas. Traditional suction cups also result in a wavy mat surface whichis more difficult for individuals and loads to traverse.

As mentioned, existing approaches to reducing movement of mats includesignificant limitations. Further, the known approaches requireadditional space, components, installation effort and expense. As aresult, significant improvement can still be made relative to reducingthe movement of mats especially in the presence of water or moisturetrapped between the mat and the floor.

In addition to the problem of slip resistant mats moving when traversedby heavy loads or wheeled carts, another drawback of known slipresistant mats relates to the manufacturing process of these mats. Thegrippers projecting from the mat backing reduce the surface area of themat in contact with the floor. When the grippers are wet, the potentialfor mat slippage and possible resulting injuries increase. Many knownmat manufacturers attempt to solve such problems by increasing thenumber of grippers on the mat backing.

To manufacture one type of slip resistant mat, a metal screen, punchedwith a plurality of small holes is used. The equipment used tomanufacture the gripper mats allows the rubber to flow there throughduring the curing process, and form the little grippers. The gripperpattern often has a number of small rubber protrusions perhaps, usuallyround, that are created by perforating a metal screen, or Teflon coatedbelt used to form the mat backing. These grippers were introduced toreduce the movement on carpet in the 1970's, and most manufacturers ofmats use some form of this design for the current standard mat. The moremetal that is removed with punching, the less resilient it is to beingdeformed and once bent, it is of no use in the manufacturing process.This has limited the open area of the screens and meant that there is aphysical limit on the pattern on the back of the mat.

Conventional manufacturing techniques have not addressed these problemsoften associated with conventional slip resistant mats and theassociated systems and methods for mat production.

Accordingly, there is a need in the art for a method and system formaking slip resistant mats positioned over residual moisture on floors.Another need exists for such mats that can withstand heavy mechanicalloads and do not move when traversed by such loads. Another need existsin the art for a system and method for making a slip resistant mat in anefficient manner. Another need exists in the art for making slipresistant mats with robust, re-usable and reliable molds, screen beltsand the like.

SUMMARY OF THE INVENTION

The object of this invention is to provide a slip resistant mat andassociated manufacturing techniques that overcome these and otherproblems in the prior art. In one aspect, this is achieved by maximizingthe surface area of the mat in contact with the floor such that insteadof less than 15% of mat to floor surface area contact with knowngripper-style mats, it is over 90% with various embodiments of thisinvention. But, unlike a smooth-backed mat, embodiments of thisinvention have a pattern of small channels on the mat backing that allowmoisture to be displaced and excellent mat contact with the floor,thereby increasing the coefficient of friction to be well in excess ofknown mats. This invention utilizes the channels to reduce the movementof the mat especially in the presence of moisture between the matbacking and the floor. The channels provide an area for any trappedmoisture to escape from between a lower surface of the mat and the floorto allow the mat to adhere to the floor surface and assist in retainingthe mat in its original position.

The size, pattern and shape specifications of the channels can be variedand they can be positioned in a variety of arrangements. The channelscan be any shape that is formed on the underside of the mat. Also, inone embodiment, the channels are positioned in regularly spaced rowsresulting in an evenly spaced arrangement, although they can be spacedin an infinite number of combinations. In one embodiment, the patternextends to the edge of the mat in order to assist in gripping the floor,particularly where the mat is exposed to cart traffic.

In another embodiment, the channels may be different sizes and shapes.The existence of multiple sizes and shapes of channels permits improvedperformance on a variety of floor surfaces since larger channels performbetter on some surfaces and smaller channels perform better on others.

One advantage of this invention is that the mat resists slipping to amuch greater extent than existing mat designs even in the presence ofmoisture between the mat and the floor. Another advantage is that itprovides the enhanced slip-resistance without adding any weight orinstallation complexity to existing mat designs. Another advantage isthat the invention does not require any permanent fastening means and istherefore easy to move to different locations. Another advantage is thatthe channels provide additional cushioning for pedestrian and vehiculartraffic. Another advantage is that the cushioning of the channels yieldsan anti-fatigue effect, thereby resulting in reduced wear and tear androutine maintenance and increased user comfort, especially for locallystationed employees spending long period of time on the mat. Anotheradvantage of the invention is that the slip-resistance is effective on awide variety of surfaces.

In other embodiments, this invention is generally drawn to a system andmethod for making a slip resistant mat. More particularly, the systemand method can include assembling parts with predetermined geometries toform a mold screen that can be used for making slip resistant mats thathave channels or other features. Each part of the mold screen can havepredetermined geometrical shapes that can be manufactured efficientlyand with reduced cost.

The raw material used to form the slip resistant mat may comprise rubberas is well known in the art. According to one exemplary embodiment, themold system of this invention allows for the rubber to have a predefinedgeometry which includes the channels or other features. This predefinedgeometry includes regions of rubber that are positioned to correspondwith the channels in the platen.

One part of the system to make the mat can include a model platen. Themodel platen may comprise a metal sheet that has a replica of theplurality of channels that form a surface of the metal sheet. Thereplica channels can be shaped to replicate the basic structure of theslip resistant pattern on the mat backing. The channels can be formed bya process that employs a computer numerical controlled (CNC) machine. Byusing a CNC machine for forming the model platen, the model platen canbe made very efficiently, precisely and with reduced cost compared toconventional machining methods.

According to one aspect of this invention, a casting system is used inwhich the aluminum plate or model platen is machined with CNC routers.The machined model platen is used to create a mold screen which has anegative of the slip resistant pattern on the mat backing. Using anegative means that the CNC machine formed replica channels are verythin and do not affect the integrity of the model platen or mold screen.A blend of silicone, with a reinforcing backing of Nomex® or Kevlar®,may be used to create the mold screen.

The replica pattern created in the model platen may be only 0.25 inchesdeep and 0.045 inches wide. The replica channel pattern is a continuousseries of lines which would not have been possible to create with knownmanufacturing techniques. The negative of the channel pattern is createdin the mold screen. Using continuous channel lines and silicone, theissue of air entrapment can be avoided which to date has been an issuewith patterns that have small objects and tolerances. The mold screenwith a negative pattern of the channels is then used to manufacture themat backing with the slip resistant channel pattern, similar to thatmachined into the model platen.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention,and the manner of attaining them, will become more apparent and theinvention itself will be better understood by reference to the followingdescription of embodiments of the invention taken in conjunction withthe accompanying drawings, wherein:

FIG. 1 is a perspective view showing a CNC router utilized according toone embodiment of this invention to form a platen utilized in themanufacture of a slip resistant mat according to this invention;

FIG. 2 is a perspective view showing one step in the process ofutilizing the platen according to one embodiment of this invention togenerate a mold to form a slip resistant mat according to variousembodiments of this invention;

FIG. 3 is a view similar to FIG. 2 showing the mold material beingspread over the platen according to one embodiment of this invention;

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3;

FIG. 5 is a perspective view of a mold utilized to form a slip resistantmat according to one embodiment of this invention;

FIG. 5A is an enlarged view of the encircled portion 5A of FIG. 5showing a negative pattern in the mold of FIG. 5;

FIG. 6 is a perspective view of a mat showing the backing formedaccording to one embodiment of this invention; and

FIG. 6A is an enlarged view of the encircled region 6A of FIG. 6 showinga pattern of channels on the mat backing of the mat of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

A slip resistant mat, system and method for making such a mat caninclude assembling parts with predetermined geometries to form a moldsystem that can be used for making slip resistant mats. The uniquegeometries of the parts which form the mold system can be manufacturedefficiently, robustly and with reduced cost. The mold system of thisinvention can be used to make slip resistant mats with increased surfacearea contact between a backing of the mat and the floor. This can be aparticularly advantageous feature to overcome residual moisture trappedbetween the mat backing and the floor to provide resistance to the matfrom slipping.

Exemplary embodiments of this invention will be described with referenceto the drawings and figures in which like numerals represent likeelements throughout the several figures. Referring now to FIG. 6 whichillustrates a perspective view of an exemplary slip resistant mat 10according to one embodiment of this invention. The exemplary slipresistant mat 10 includes an upper surface 12 and a lower or backingsurface 14 for the mat 10. The upper surface 12 may have a yarn, carpetor other fabric layer 15 laminated or otherwise bonded to a supportlayer 16. The mat backing 14 of the support layer 16 includes the slipresistant pattern 18 to inhibit slipping of the mat 10 relative to afloor 20 on which it is supported. While this is one exemplaryembodiment of a slip resistant mat according to this invention, those ofordinary skill in the art will appreciate that a large variety of othermat designs, styles, constructions and configurations according tovarious aspects of this invention are within the scope of thisinvention.

The slip resistant mat 10 according to various embodiments of thisinvention includes the mat backing 14, one embodiment of which is shownin FIGS. 6-6A. The mat backing 14 includes the pattern 18 in the form ofa series of recessed channels 22 which, in the embodiment shown in FIG.6A, each channel 22 is generally parallel to an adjacent channel in azig-zag arrangement. The channels 22 are formed around rows ofprojections 24 and each row of projections is a series ofhexagonal-shaped protuberances 26 joined to an adjacent hexagonal-shapedprotuberance 26 by a bridge 28. The protuberances 26 and bridges 28combine to form a lower surface 29 of the mat 10 which contacts thefloor surface 20. One advantageous aspect of the mat backing 14according to various embodiments of this invention is that thecombination of hexagonal-shaped protuberances 26 and bridges 28 whichproject from the bottom surface of the mat 10 offers increased surfacearea contact between the mat backing 14 and the floor 20. As previouslynoted, the surface area contact provided by the lower surface 29according to various embodiments of this invention for the mat backing14 may be as high as 90% or greater. However, channels 22 formed in themat backing 14 provide for the dissipation and channeling of anymoisture or water trapped between the lower surface 29 and the floor 20thereby allowing for the projections 24 on the mat backing 14 to provideincreased resistance to slippage of the mat 10 relative to the floor 20when the moisture is trapped within the channels 22. Those of ordinaryskill in the art will readily appreciate that the particular geometries,shapes, dimensions and specifications of the mat backing may be variedfrom those shown and described herein while still being within the scopeof this invention.

Referring to FIGS. 1-5A, a method and system according to variousembodiments of this invention for manufacturing the slip resistant mat10 with a mat backing 14 of the type previously described begins withthe production of a model platen 30. In one embodiment, the model platen30 is fabricated from a metal plate 32, such as a ¼ inch thick 5052aluminum plate which is machined with a CNC router 34 to have aconfiguration to replicate to the mat backing 14 as previouslydescribed. The CNC router 34 machines the plate 32 into the model platen30 which, according to one embodiment, involves utilizing a 1/16 inchbit on the router 34 to form a replica 18 a of the slip resistantpattern 18 corresponding to the mat backing 14 to a depth ofapproximately 0.025 inches on the model platen 30. A pocket 36, about0.070 inches deep, is machined on the model platen 30 to the desiredlength and width of the mat 10. The model platen 30 is utilized toproduce a screen mold 38 (FIGS. 5-5A). The screen mold 38 includes anegative 18 b of the shape, design and configuration of the slipresistant pattern 18 on the mat backing 14.

As shown in FIG. 2, once the model platen 30 is completed, it has thepocket 36 the size of the desired screen mold 38 with the replica 18 aof the mat backing 14 configuration machined on the model platen 30. Thereplica pattern 18 a on the model platen 30 is the pattern 18 to beproduced on the mat backing 14 to advantageously displace moisture andhold the mat 10 to the underlying floor 20. The depth of the pocket 36machined into the model platen 30 provides adequate screen mold 38strength for durable screen mold 38 production; however, the depth ofthe pocket 36 is thin enough to minimize any negative influences ofexcessive insulation in the press process during the production of theanti-slip mat 10.

Referring to FIGS. 2-5A, the machined model platen 30 is utilized toform and produce the screen mold 38 which has the negative 18 b of theslip resistant pattern 18 on the mat backing 14. The model platen 30 isinitially filled with mold material 40 to be cast into the model platen30. In one embodiment, the mold material 40 utilized in the productionof slip resistant mats 10 according to this invention is a two-partcurable silicone. After the two parts of the silicone are mixed, themixture is spread into the model platen 30 before it begins to set.Specifically, as shown in FIGS. 2 and 3, the silicone mold material 40is pre-spread into the pattern of replica channels 18 a machined intothe model platen 30. Since the screen mold 38 will be relatively thin, a0.070 inch cavity depth with a 0.025 inch depth negative pattern 18 baccording to one embodiment, there is little depth in the model platen30 to entrap air in the mold material 40. To further minimize thechances of air entrapment, a tool such as a trowel 41 as shown in FIG. 2is used to pre-spread at 43 the mold material 40 into the replicachannel pattern 18 a of the model platen 30 before a solid portion ofthe screen mold 38 is filled with the mold material 40. The moldmaterial 40 pre-spread into the model platen 30 as shown particularly inFIG. 2.

Subsequently, a straight edge tool 44 as shown in FIG. 3 spreads themold material 40 into the remaining portion of the pocket 36 formed inthe model platen 30 and the thin nature of the cavity formed by thepocket 36 allows any air entrapped within the mold material 40 to escapebefore the mold material 40 cures. An enlarged cross-sectional view ofthe relationship of the pocket 36 and mold material 40 within the modelplaten 30 is shown in FIG. 4.

After the mold material 40 has been spread into the model platen 30 andallowed to cure, the screen mold 38 is removed from the model platen 30and includes the negative pattern 18 b of the slip resistant pattern 18to be formed into the mat backing 14 as shown particularly in FIG. 5.FIG. 12 shows the entire screen mold 38 with the negative pattern 18 bof the mat backing 14. The finished screen mold 38 is the appropriatesize of the desired slip resistant mat 10 to be formed.

The screen mold 38 of FIG. 5 according to one embodiment of thisinvention is utilized to form the rubber slip resistant mat 10 andassociated mat backing 14 according to well known manufacturingtechniques. The screen mold 38 is likewise shown in FIG. 5A.Advantageously, the screen mold 38 has sufficient durability anddefinition to yield a detailed and precise channel pattern 18 in theslip resistant mat 10. The mat backing 14 of the finished mat 10 has thesame pattern 18 as the replica pattern 18 a which was originallymachined into the model platen 30 and a negative 18 b of the patternformed in the screen mold 38. By using a screen mold 38 that is bothsolid backed as shown in FIG. 4 and designed to dispel any air bubbleswithin the mold material 40 which is a high release silicone rubber, themat backing 14 has a clean, crisp appearance with little or no residualrubber flashing to interfere with contact to the floor 20.

The pattern 18 on the mat backing 14 of the slip resistant mat 10according to various embodiments of this invention extends to the edgeof the mat 10 to assist in gripping the floor 20, especially for thoseapplications where the mat 10 will be exposed to cart and heavy traffic.The relatively thin width dimension of the replica pattern 18 a machinedinto the pocket 36 of the model platen 30 does not affect the integrityof the screen model 38 which utilizes the mold material 40 of a siliconeblend with a reinforcing backing of Nomex® or Kevlar® to create the matbacking 14 of the slip resistant mat 10 according to various embodimentsof this invention.

From the above disclosure of the general principles of this inventionand the preceding detailed description of at least one embodiment, thoseskilled in the art will readily comprehend the various modifications towhich this invention is susceptible. Therefore, we desire to be limitedonly by the scope of the following claims and equivalents thereof.

We claim:
 1. A slip resistant mat comprising: an upper surface tosupport traffic thereon; a backing integrally molded on an opposite faceof the mat from the upper surface and adapted to be juxtaposed to afloor surface on which the mat is positioned; and a slip resistantpattern formed on the backing to inhibit slipping of the mat relative tothe floor surface when positioned thereon, wherein the slip resistantpattern further comprises a repeating pattern of projections andchannels extending over a substantial portion of the backing of the matsuch that the projections in combination form a lower surface of the matwhich contacts the floor when the mat is positioned thereon; whereinmoisture trapped between the mat and the floor is dispersed away fromthe projections and into the channels when the mat is positioned on thefloor surface to thereby inhibit movement of the mat relative to thefloor surface.
 2. The slip resistant mat of claim 1 wherein the lowersurface formed by the combination of the projections is at least about90% of the surface area of the backing of the mat.
 3. The slip resistantmat of claim 1 wherein the upper surface further comprises: a fabriclayer.
 4. The slip resistant mat of claim 1 wherein the projectionsfurther comprise: a plurality of spaced hexagonal-shaped protuberances;and a plurality of bridges each of which joins together two adjacenthexagonal-shaped protuberances.
 5. The slip resistant mat of claim 1wherein the channels are in a zig-zag arrangement.
 6. The slip resistantmat of claim 1 wherein the projections and the channels extend generallydiagonally across the backing of the slip resistant mat.
 7. A method ofmaking a slip resistant mat having a slip resistant pattern on a backingof the mat, the method comprising the steps of: forming a model platenwith a replica of the slip resistant pattern; forming a screen mold withthe model platen in which the screen mold has a negative of the slipresistant pattern formed by the replica of the slip resistant pattern;and forming the slip resistant mat with the screen mold in which thenegative of the slip resistant pattern forms the slip resistant patternon the backing of the mat.
 8. The method of claim 7 wherein the formingof the model platen step is accomplished with a CNC router.
 9. Themethod of claim 7 wherein the model platen is formed from a metal plate.10. The method of claim 7 further comprising: forming a pocket in themodel platen with the replica of the slip resistant pattern therein. 11.The method of claim 7 further comprising: applying mold material to themodel platen; and curing the mold material on the model platen to formthe screen mold.
 12. The method of claim 11 wherein the mold material isa two-part curable silicone mold material in which one part is siliconeand another part is Nomex® or Kevlar®.
 13. The method of claim 7 furthercomprising: minimizing entrapped air in the screen mold in conjunctionwith the forming of the screen mold step.
 14. The method of claim 11wherein the forming of the screen mold step further comprises: spreadingthe mold material onto the model platen with a tool.
 15. The method ofclaim 7 wherein the screen mold has a substantially solid backingopposite from the negative of the slip resistant pattern formed thereon.16. The method of claim 7 wherein the model platen has a substantiallysolid backing opposite from the replica of the slip resistant patternformed thereon.
 17. A slip resistant mat comprising: an upper surfaceincluding a fabric layer to support traffic thereon; a backingintegrally molded on an opposite face of the mat from the upper surfaceand adapted to be juxtaposed to a floor surface on which the mat ispositioned; and a slip resistant pattern formed on the backing toinhibit slipping of the mat relative to the floor surface whenpositioned thereon, wherein the slip resistant pattern further comprisesa repeating pattern of projections and channels extending over asubstantial portion of the backing of the mat such that the projectionsin combination form a lower surface of the mat which contacts the floorwhen the mat is positioned thereon; wherein the lower surface formed bythe combination of the projections is at least about 90% of the surfacearea of the backing of the mat; wherein moisture trapped between the matand the floor is dispersed away from the projections and into thechannels when the mat is positioned on the floor surface to therebyinhibit movement of the mat relative to the floor surface.
 18. The slipresistant mat of claim 17 wherein the projections further comprise: aplurality of spaced hexagonal-shaped protuberances; and a plurality ofbridges each of which joins together two adjacent hexagonal-shapedprotuberances.
 19. The slip resistant mat of claim 18 wherein thechannels are in a zig-zag arrangement.
 20. The slip resistant mat ofclaim 19 wherein the projections and the channels extend generallydiagonally across the backing of the slip resistant mat.
 21. The methodof claim 7 wherein the forming of the slip resistant mat step isaccomplished in a batch process.